A two-stage cold forging process including heading and backward extrusion stages was simulated with emphasis on defect formation during backward extrusion for forming gear-like profile.

An automatic three-stage hot forging process was simulated in a fully automatic way, including dwelling before or after forming, transferring, etc. Non-isothermal analysis was conducted. The figure shows the metal flow lines and the animation represents the variation of temperature with the time.

A combined forging process for a set of bearing races, a combination of hot and cold forgings, was simulated. The first three stages are relying on hot forgings while the left are of cold forgings. Metal flow lines were shown in the figure.

A complex cold forging process was simulated by a team of junior students in their related course. The process was came from a forging handbook. The color means effective strain.

An automatic multi-stage cold forging process with spring-attached dies was simulated. The intermediate die moves down following the force balance between the push down force and the spring force.  

Cold forging of a housing is simulated in a fully automatic way, which involves several backward extrusion stages and a piercing stage. The effective strain and metal flow lines were described in the figure.

A precision forging simulation was conducted for a precision shaft which has both stepped ends. A careful consideration should be taken for the simulation because this process is exposed to numerical problem when a rigid-plastic finite element method is employed.

A complicated forging process which involves a piercing stage was simulated in a fully automatic way. Variation of effective strain with stroke was shown in this figure.

  A ball-stud forging process which involves neck forming was simulated.

 A ball-stud with cavity in the head was automatically simulated. The effective strain was shown in the figure.